Apparatus and method for orienting and case packing eared containers

ABSTRACT

An apparatus and method is disclosed for receiving bailed containers in a single file array from a delivery system and to orient said containers so that they are delivered to a Y-divider for separation into two groups for single file alignment and delivery to a transfer system for moving them into the open ends of an automatically erected carton. After filling the carton with either four or two containers the carton is advanced to a closing, sealing and delivering mechanism. In this automatic mechanism the cartons for the case packing operation are placed in a delivery station from which they are advanced to an erecting station which is automatically actuated in response to the delivery of bailed containers to and through the orienting apparatus. The glued and sealed cartons may be delivered to a conveyor or pallet. The containers as they are arranged in the carton may have their bails facing into the corners of the carton or facing toward the center of the carton. Apparatus is shown where changes in the apparatus and operation permit carton delivery and feeding means to also erect small size cartons and fill these smaller size cartons with only two containers.

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Heisler atet n91 [76] Inventor: Raymond A. Heisler, 657 Dakota Trl., Franklin Lakes, NJ. 07417 22 Filed: June 26,1973

21 Appl. No.: 373,752

[52] US. Cl 53/26, 53/29, 53/159, 53/186, 53/383, 53/387, 198/31 AC, 198/235 [51] Int. Cl...'.. B65b 5/08, 1365b 35/56, B651) 43/28 [58] Field of Search 53/159, 61, 67, 26, 29, 53/186, 252, 284, 247, 383, 387; 198/24, 21 AC, 235

[56] References Cited UNITED STATES PATENTS 3,136,105 6/1964 Eckhoff 198/24 X 3,209,512 10/1965 Ferguson, Jr. et a1. 53/159 X 3,284,985 11/1966 Roth 53/159 X 3,289,810 12/1966 lannucci 53/61 X 3,462,912 8/1969 Anderson 53/167 X 3,740,919 6/1973 Heisler 53/159 Nov. 119, 1974 Primary ExaminerGil Weidenfeld Attorney, Agent, or FirmRalph R. Roberts [5 7] ABSTRACT An apparatus and method is disclosed for receiving bailed containers in a single file array from a delivery system and to orient said containers so that they are delivered to a Y-divider for separation into two groups for single file alignment and delivery to a transfer system for moving them into the open ends of an automatically erected carton. After filling the carton with either four or two containers the carton is advanced to a closing, sealing and delivering mechanism. In this automatic mechanism the cartons for the case packing operation are placed in a delivery station from which they are advanced to an erecting station which is auto matically actuated in response to the delivery of bailed containers to and through the orienting apparatus. The glued and sealed cartons may be delivered to a conveyor or pallet. The containers as they are arranged in the carton may have their bails facing into the corners of the carton or facing toward the center of the carton. Apparatus is shown where changes in the apparatus and operation permit carton delivery and feeding means to also erect small size cartons and fill these smaller size cartons with only two containers.

39 Claims, 36 Drawing Figures PATENTEL 243V 1 91974 SHEET 02 OF 18 PATENTE' NOV 1 91974 SHEET 05 0F 18 PATENTEL LEV 1 9 I974 SHEET [16 0F 18 PATENTE xsv 1 9 I974 SHEETv 07 0F 18 PAIENIE m1 91 974 HEE 09 0F 18 PATENTL LEV I 91374 SHEET 12 HF 18 moi PATENTEL 9'974 3.848 394 SHEET 13 HF 18 I PAIENIE 249V 1 91914 sum 11; HF 18 PATENK 50V 19 I974 SHEET 15 0F 18 sum 16 0F 18 3 848,3

I PATENTEL HEY I 91374 PATENIMUMW sum 170F18 3848-394 0 no N PATENTEB rm 1 91914 SHEET 180F 18 cwm APPARATUS AND METHOD FOR ORIENTING AND CASE PACKING EARED CONTAINERS CROSS-REFERENCE TO RELATED APPLICATIONS This application relates to two associated applications by the same inventor as the present application. A parent application given Ser. No. 204,892 and filed Dec. 6, 1971 is now U.S. Pat. No. 3,740,919 as issued on June 26, 1973. A divisional application and con-.

tinuation-in-part of this parent application given Ser. No. 336,246 was filed on Feb. 27, 1973 now Pat. No. 3,814,000. To the extent applicable the subject matter of these referenced applications are incorporated by reference into this application.

BACKGROUND OF THE INVENTION 1. Field of the Invention With reference to the classification of art as established in the U.S. Pat. Office the field of art to which this invention pertains is found inthe general Class of Package Making (Class 53) and more particularly in the subclass of automatic or trigger control (subclass 52) and more particularly in the further subclass of group feed triggered by completion of group (subclass 61). Another pertinent subclass in this general class is group forming of contents unit (subclass 26).

2. Description of the Prior Art In the prior art, apparatus is known wherein eared containers with attached bails are oriented and fed into erected cartons which are then sealed. The mechanism for orienting and feeding these containers is usually complex, expensive and often is capable of an operating speed which is less than that now achieved in filling lines having automatic bail-applying mechanism. An example of said bail-applying mechanism is found in my U.S. Pat. No. 3,241,578 which issued Mar. 22, 1966. This bail-applying mechanism is used on hundreds of production lines such as paint filling lines many of which, if not all, are presently operating at speeds of 75 or more containers per minute. It is desirable and necessary that case packing apparatus used with these filling lines have sustained operating capacities as great as and preferably in excess of those operating speeds.

Several recent U.S. Patents pertaining to apparatus for article positioning and case loading have been issued. Among these patents are U.S. Pat. No. 3,209,512 to Ferguson, Jr., et al which issued on Oct. 5, 1965; U.S. Pat. No. 3,284,985 to Roth which issued on Nov. 15, 1966 and also U.S. Pat. No. 3 ,462,912 to Anderson which issued on Aug. 26, 1969. In these and other known systems it is the intent to receive bailed eared containers and to orient these containers so that with their bails laid against the side of the containers these containers, as a grouping, may be fed into an open erected carton and with the containers in a determined oriented condition the carton is closed and sealed. Insofar as is known by the applicant the apparatus aboveidentified and shown in these patents as well as others which have been used in industry have not provided the reliability and speed necessary for present paint filling lines.

In the present invention and as reduced to practice, the rate for the orienting and placing the bailed containers in an erected carton is at least 10 percent greater than the containers per minute now found on some of the faster paint filling lines. Thepresent invention receives bailed containers on a conveyor lead ing froma bail-applying mechanism or other container advancing means. In a preferred embodiment these containers with their bails in a vertical condition are brought to an alternate feed device whereat the containers are alternately delivered by one of two accumulating conveyors to an orienting mechanism where they are oriented in a determined manner and arranged in groups 'of two. As oriented pairs, these containers are then fed into opposite open sides of an erected carton. After the carton has been filled with four containers the carton is advanced to a closing, sealing and delivering mechanism. The rate of operation of the mechanism of the present invention is established by the receipt of the containers from the bail-applying mechanism or other feeder lines. The bailed containers, as oriented, may be arranged in the carton with their bails facing into the four corners of the carton or if desired the bails may be facing toward the center of the carton.

In the present invention there is also disclosed adjustable apparatus whereby at one setting two containers are inserted into an appropriately formed and. erected carton which is then closed and sealed. In the other setting four containers are simultaneously inserted into an erected carton which is then closed and sealed.

SUMMARY OF THE INVENTION This invention may be summarized at least in part with reference to its objects.

It is an object of this invention to provide, and it does provide, an orienting apparatus adapted to receive bailed eared containers aligned in a determined array and to feed these containers in a single file to an apparatus wherein the containers are oriented in a desired array and arranged into two columns and as oriented pairs are discharged simultaneously into the open sides of an erected carton. The filled carton with four oriented containers is then transferred to closing, gluing and discharging operations.

It is a further object of this invention to provide, and it does provide, orienting apparatus adapted to receive bailed eared containers delivered in single file array and to reorient the containers so that they are delivered two at a time and simultaneously as oriented pairs are fed to and into opposite sides of an erected carton after which the flaps of the carton are closed and glued as and after which the carton is advanced for delivery to a conveyor or pallet. The carton erecting equipment includes a flat carton receiving station whereat a supply of cartons is stored in a substantially vertical condition and from which they are fed to a carton chute in which a supply of cartons is supported in a more or less hori zontal condition. From the bottom of the chute the cartons are engaged by suction cups carried on an arm which is cycled so as to withdraw a carton from the chute and erect this same carton while delivering to a carton conveyor apparatus.

The orienting and case packing apparatus and method provided by this invention includes a receiving conveyor adapted to receive bailed containers in a single file array and with alternating diverter feed containers to and through a Y-type conveyor in equal numbers to alternate sides of a carton erecting station. On the two branches of the conveyor the containers are 

1. Apparatus for receiving containers in a single file array and to equally divert said containers to two conveyors and to then insert an equal number of containers substantially simultaneously into the opposite open ends of an erected carton and thereafter delivering said carton to closing, gluing and sealing means after which the carton is delivered from the apparatus, said apparatus including: (a) a delivery means adapted to deliver a supply of eared containers to a receiving station; (b) a diverting means at said receiving station, said diverting means adapted to alternately feed every other container to and along a first transporting conveyor disposed along one side of the apparatus and to alternately feed the other container to and along a second transporting conveyor disposed along the other side of the apparatus; (c) means for erecting and delivering an erected carton to an inserting station whereat the carton has both its ends retained in an open condition, each open end of the carton positioned adjacent a container inserting apparatus; (d) means in association with said conveyor for presenting each container to an inserting station with the ears of the container in a determined oriented condition; (e) circuit control means adapted to determine that a required quantity of containers are in place in way of each of the inserting apparatus and that an open erected carton is in its required place; (f) inserting apparatus associated with each transporting conveyor, each apparatus having an ear engaging arm disposed to slidably engage the side of a container as the container is moved from the conveyor to and into the open end of a carton, said engaging arm engaging one side of an ear to orient the axis of the ear at a determined angle to the side of the receiving carton, and an ear retaining finger associated with the ear engaging arm, said finger and arm retaining an ear of the container at a determined orientation in the carton during insertion of the container to achieve the carton filled condition, and (g) means for moving the filled carton to sealing and delivery means.
 2. Apparatus for receiving and packing eared containers into cartons as in claim 1 in which the eared containers are also provided with bails and in which the orienting of the containers on the conveyor includes receiving the bailed containers with their bails disposed in a vertical manner and in which said vertical bails are retained in a guide rail system to bring the oriented containers to a determined orieNted position and prior to the inserting station apparatus is provided for turning the bails to the side of the container.
 3. Apparatus for receiving and packing eared containers into cartons as in claim 2 in which the turning of the bails from their vertical condition to a side condition also insures that the containers are delivered to the inserting station with their ears substantially aligned with the axis of the conveyor.
 4. Apparatus for receiving and packing eared containers into cartons as in claim 3 in which each inserting apparatus is adapted to receive and insert two adjacent containers into the side of an open carton.
 5. Apparatus for receiving and packing eared containers as in claim 4 in which the inserting mechanism engages the two containers and pushes the containers toward and into the open end of the carton, and in which the apparatus includes a slide plate positioned to slidably engage the upper rim of the advancing container in such a manner as to cause the container to rotate on its axis as it is moved under and past this slide plate.
 6. Apparatus for receiving and packing eared containers as in claim 5 in which there is a slide plate for each of the two containers with the slide plates arranged side-by-side and substantially equidistant from the theoretical center line between the containers.
 7. Apparatus for receiving and packing eared containers as in claim 6 in which the inserting mechanism further includes a bail retaining bar disposed to engage and slidably retain the bail of each container against the side of the container during the inserting motion of the inserting mechanism.
 8. Apparatus for receiving and packing eared containers as in claim 7 in which each of the inserting mechanism is for two containers and includes a pair of arcuate members each having arcuate segments disposed to engage and retain the containers in a determined side-by-side spacing and with each inserting mechanism having the ear retaining finger as a cammed ear retaining finger disposed to be lifted and to drop into ear retaining condition during the rotation of the container and in which the ear engaging arm as it engages the ear positions the axis of the ears of the container at substantially 45* to the side of the carton.
 9. Apparatus for receiving and packing eared containers as in claim 8 in which the bail retaining bar is spring biased to its initial forward condition and in which the cammed ear retaining finger is pivotally retained at one end so as to be lifted by the ear movement against a cam surface and by gravity the retaining finger falls into place.
 10. Apparatus for receiving and packing eared containers as in claim 9 in which the inserting apparatus includes a stop bar which is carried by the apparatus so as to impede the progress of succeeding advancing containers into the path of the inserting mechanism until the mechanism has been returned to its initial inserting condition.
 11. Apparatus for receiving and packing eared containers into cartons as in claim 3 in which the cartons are adapted to receive only two containers with one container inserted into each end of an erected carton and in which each inserting apparatus is adapted to receive and insert a single container into the open end of an erected carton.
 12. Apparatus for receiving and packing eared containers into cartons as in claim 11 in which the inserting mechanism engages a single container and pushes this container toward and into the open end of the carton and in which the apparatus includes a slide plate positioned to slidably engage the upper rim of the advancing container in such a manner as to cause the container to rotate on its axis as it is moved under and past this slide plate.
 13. Apparatus for receiving and packing eared containers into cartons as in claim 12 in which the container inserting mechanism further includes a container retaining bar disposed to engage and slidably retain the bail of the container against the side of said container during the inserting motion of the inserting mechanism.
 14. Apparatus for receiving and packing eared containers into cartons as in claim 13 in which the container inserting mechanism further includes upper and lower arcuate members each having an arcuate receiving contour disposed to engage and retain the container in a determined position in the inserting mechanism during insertion.
 15. Apparatus for receiving and packing eared containers into cartons as in claim 14 in which the conveyor transporting the containers is provided with a removable stop which when in the path of the container causes the advance of the container to be impeded and in which the inserting apparatus includes a stop bar which is carried by said apparatus so as to impede the progress of succeeding advancing containers into the path of the inserting mechanism until the mechanism has been returned to its initial inserting condition.
 16. Apparatus for receiving and packing eared containers into cartons as in claim 1 in which the orienting of the containers on the conveyor includes a rub rail which engages the bottom rim of the container in such a manner as to cause the container to rotate around its axis to bring an ear of the container against an ear stop rail which then engages the ear of the advancing container to retain the desired container orientation until the container reaches a determined position where this orienting apparatus is discontinued to permit the now oriented containers to proceed to the inserting station.
 17. Apparatus for receiving and packing eared containers into cartons as in claim 16 in which the orienting of the containers at the inserting station further includes a second rub rail by which the leading container is caused to be turned about a quarter turn from the orientation of the second container in the series to be inserted, this orientation resulting in the ears to be engaged by the inserting mechanism being toward the center line of the inserting mechanism.
 18. Apparatus for receiving and packing eared containers into cartons as in claim 17 in which the container inserting mechanism includes a fixed ear retaining finger disposed to engage the adjacent side wall of each of the containers while each ear is engaged by one of a pair of ear engaging arms which is moved from a limiting stop and against a spring bias.
 19. Apparatus for receiving and packing eared containers into cartons as in claim 18 in which each inserting apparatus includes a stop bar which is carried by the apparatus so as to impede the progress of succeeding advancing containers into the path of the inserting mechanism until the inserting mechanism has been returned to its initial inserting condition.
 20. Apparatus for receiving and packing eared containers as in claim 1 in which there is provided adjustment means whereby the carton delivery chute is able to receive and dispense cartons of various sizes including cartons for two as well as for four containers and in which the conveyors are provided with selective stops whereby a first inserting apparatus is adapted to insert only one container into a carton and means is provided for removing and replacing this inserting apparatus with a second apparatus which is adapted to insert two containers into the open end of an appropriately sized carton.
 21. Apparatus for receiving and packing eared containers as in claim 1 in which the circuit is provided with a detecting means which is so positioned that with one container in inserting position in an inserting station adapted for only inserting one container and said detecting means is actuated by the presence of an adjacent succeeding container, the detecting means causes a signal by which this conveyor transport system is shut down.
 22. Apparatus for receiving and packing eared containers as in claim 21 in which the circuit is provided with an adjacent container detecting means at each of the opposite inserting stations.
 23. Apparatus for receiving and packing eareD containers as in claim 1 in which the circuit is provided with an adjacent container detecting means which is so positioned that with two containers in inserting position in an inserting station adapted for inserting two containers and said detecting means is actuated by the presence of an adjacent succeeding container the detecting means causes a signal by which the conveyor transport system is shut down.
 24. Apparatus for receiving and packing eared containers as in claim 23 in which the circuit is provided with adjacent container detecting means at each of the opposite inserting stations.
 25. The method of receiving containers in a single file array to equally divert said containers to two conveyors and to then insert an equal number of containers substantially simultaneously into opposite open ends of an erected carton and thereafter delivering said carton to closing, gluing and sealing means after which the carton is delivered from the apparatus, said method including the steps of: (a) delivering a supply of eared containers to a receiving station; (b) feeding the received containers to a diverting means and from there feeding these containers alternately with every other container fed to and on a first transporting conveyor disposed along one side of the apparatus and feeding alternately the other containers to and along a second transporting conveyor disposed along the other side of the apparatus; (c) erecting and delivering an erected carton to an inserting station with the carton having both its ends retained in an open condition, each open end being adjacent a container inserting apparatus; (d) orienting and presenting each container to an inserting station with its ears in an oriented condition; (e) controlling by a circuit control means the receipt and presence of a required quantity of containers in place in way of each of the inserting apparatus and that an open erected carton is in its required place; (f) upon actuation of the circuit control causing inserting apparatus associated with each transporting conveyor to be actuated and positioning on each apparatus an ear engaging arm disposed to slidably engage the side of a container as the container is moved from the conveyor to and into the open end of a carton; (g) engaging one side of an ear with the engaging arm so as to orient the axis of the ear at a determined angle to the side of the box; (h) positioning an ear retaining finger so that with the ear engaging arm the finger and arm will engage and retain the ear and attached container at a determined orientation in the carton during insertion of the container into the carton, and (i) moving the filled carton to flap folding, sealing and delivering operations.
 26. The method of receiving and packing containers as in claim 25 which further includes the step of insuring that each of the containers have bails and that these bails are disposed in a vertical manner and the further step of maintaining the containers in an oriented condition on the conveyor by retaining the bails in a guide rail system as they are moved along the conveyor.
 27. The method of receiving and packing containers as in claim 26 which includes the further step of turning the bails to the outer side of the conveyor and container as each container is brought on and by the conveyor to the inserting station.
 28. The method of receiving and packing containers as in claim 27 which further includes feeding two containers to and past sensing means to insure that two adjacent containers are present in the inserting apparatus before initiating the inserting movement of the apparatus.
 29. The method of receiving and packing containers as in claim 28 which further includes the step af arranging the containers with their ears substantially aligned with the axis of the conveyor.
 30. The method of receiving and packing containers as in claim 25 which includes arranging a slide plate so as to slidably and frictionally engage the upper rim of an advancing container during its insertion movement and by frictional restraint rotating the container on its axis for about one-eighth revolution.
 31. The method of receiving and packing containers as in claim 30 which includes bringing two adjacent containers to the inserting station and arranging two slide plates so that during the container inserting movement by the inserting apparatus one container turns clockwise around its axis and the other adjacent container turns counterclockwise around its axis.
 32. The method of receiving and packing containers as in claim 31 which further includes the engaging and retaining of the bail against the side of the container during the insertion of the container into the carton.
 33. The method of receiving and packing containers as in claim 25 which further includes providing a stop means adjacent the inserting mechanism to impede progress of the containers along the conveyor and in way of the inserting mechanism while the mechanism is in its inserting cycle.
 34. The method of receiving and packing containers as in claim 25 which includes the step of providing only cartons which will receive and retain two containers with one container inserted into each open end of the carton and further arranging each opposite inserting apparatus so as to engage and retain only one container and insert that container into the erected carton.
 35. The method of receiving and packing containers as in claim 25 which includes the further step of orienting the containers as they travel along each conveyor by arranging a rub rail to tangentially engage the bottom of the advancing container to cause the container to rotate around its axis and placing an ear engaging rail in way of the rotating ear to stop the rotation of the container at a determined orientation position for delivery to the inserting station.
 36. The method of receiving and packing containers as in claim 35 which includes the further step of arranging an additional rub rail at an inserting station for two containers said additional rub rail causing rotation of the leading container of about one-quarter revolution.
 37. The method of receiving and packing containers as in claim 36 which further includes positioning an ear retaining finger so as to engage adjacent side walls of the containers and also one side of one of the ears on each of the containers and arranging pivotally mounted ear engaging arms to engage the other sides of these ears to establish a determined orientation of the container in the carton.
 38. The method of receiving and packing containers as in claim 25 which includes the further step of detecting one container in the inserting station adapted for only inserting one container and further arranging another detecting means so as to detect the presence of an adjacent succeeding container and when so detected initiating a signal to cause the conveyor transport system to be shut down.
 39. The method of receiving and packing eared containers as in claim 25 which includes the further step of detecting two containers in the inserting station adapted for inserting two containers and further arranging another detecting means so as to detect the presence of an adjacent succeeding container before initiation of the inserting mechanism and when said adjacent container is detected initiating a signal to cause the conveyor transport system to be shut down. 